Roof object support system

ABSTRACT

A support block for supporting objects on a roof is a moulded elastomeric block with a substantially hollow core. The support block can be used as is or in a system whereby a galvanized steel channel is secured to the top wall of the block accommodating the mating of a variety of clamps. In some embodiments, the block is elongate and generally flat and supports a roof mounted object thereon when two or more blocks are supported parallel and spaced apart from one another with the object spanning between the blocks.

This application is a continuation of U.S. parent application Ser. No.11/518,444, filed Sep. 11, 2006 and issued under U.S. Pat. No. 7,866,093which is a continuation-in-part of U.S. parent application Ser. No.10/703,479, filed Nov. 10, 2003 and issued under U.S. Pat. No.7,168,210.

FIELD OF THE INVENTION

The present invention relates to a vibration damping support systemusing blocks for supporting objects found on rooftops, for examplepipes, walkways, HVAC equipment, various conduits and the like and fordampening vibration of the objects.

BACKGROUND

Various service units are found on the roofs of buildings, particularlycommercial buildings. These service units will often have pipes andductwork that snake along the rooftop. Furthermore, roof walkway systemsare often present to facilitate access to the service units. Theserooftop objects usually require supports to prevent damage to the roofsurface.

The simplest support solution is the use of blocks of wood to support anobject at intervals along its length. Although this simple supportdevice has a number of drawbacks. A rooftop object being supported oftenvibrates causing vibrations to be transmitted through the block of wood.The result is excessive noise and movement of the block. It isconceivable that the block could move enough that it no longer supportsthe object it is intended to. Furthermore, this excessive movement maycause damage to the roof's surface requiring expensive repairs.

The wood blocks could be nailed to the roof but this could cause futureleaks if not sealed properly. In any event, wood will deteriorate overtime due to weathering and could possibly break loose.

Support systems according to the present invention are intended tomitigate these problems.

SUMMARY

According to one aspect of the present invention there is provided asupport system in combination with a roof object on a roof, the supportsystem comprising:

a support block having a flat bottom and a flat top;

the support block being formed as a single piece of a self-dampingelastomeric material;

the support block being supported between the roof object and the roofsuch that the roof object is supported on the flat top of the supportblock and the elastomeric material forming the support block is arrangedto dampen vibration between the roof object and the roof.

The support system is configured for supporting vibrating objectsthereon, for example rooftop mechanical equipment for a building whileprotecting the roof from damage as a result of the vibration of the roofobject. The elastomeric material reduces the transmission of vibrationsfrom the supported object to the roof surface, thereby extending rooflife. The hollow design enhances the vibration dampening qualities ofthe support block. Furthermore, the hollow design greatly reduces theshipping weight of the support blocks. Preferably, the support block ismoulded as a single length from an elastomeric material, for examplerecycled tires. The single length can be cut into custom length unitsdepending on the application. The support block is UV resistant toprevent photo-degradation. The use of recycled materials provides for anenvironmentally friendly method of manufacturing.

The block may be secured to the roof with adhesive in some applications.

The block may comprise hollow cavities formed in the flat bottom of theelastomeric material.

The elastomeric material may comprise recycled tires.

A mounting channel formed of rigid metal may be mounted to the flat topof the support block with the roof object being coupled to the mountingchannel by a supporting bracket. Preferably, the channel is generallyU-shaped in cross section, having a base secured to the flat top of thesupport block and a pair of spaced apart upright flanges spanning upwardfrom the base to an open top end of the channel.

Preferably, the channel is made from galvanized steel to reduce theeffects of weather corrosion. The terms “clamp” or “bracket” refer to avariety of different devices, for example pipe clamps, cable clamps,electrical fittings, saddles, spring bolts, beam clamps, roller clamps,and variable angle support legs.

When there are provided two support blocks, each formed of a singlepiece of self damping elastomeric material, a channel may be arranged tospan between the two support blocks for interconnecting the blocks andsupporting the roof object thereon.

In one embodiment, the block is elongate in a longitudinal direction inwhich the flat top and flat bottom are wider in a lateral direction thana height of the support block between the flat top and the flat bottom.Preferably width of the block in the lateral direction is plural timesthe height of the block and length of the block in the longitudinaldirection is plural times a width of the block in the lateral direction.

The block may include through channels formed in the flat bottom of theblock in communication between opposing sides of the block.

When the block is elongate in a longitudinal direction, the throughchannels preferably extend generally perpendicularly to the longitudinaldirection between opposing sides of the block.

The through channels may include a pair of mouths at opposing sides ofthe block respectively which are wider in cross section than a mainportion of the channel spanning between the mouths so that each mouthtapers inwardly from the respective side of the block to the mainportion of the channel.

There may be provided a hollow cavity formed in the flat bottom of theelastomeric material between each adjacent pair of the channels.

The block may include a plurality of ribs of elastomeric material formedin the flat top of the support block which extend in the longitudinaldirection of the support block.

The block may also include a pair of retainer lips protruding upwardlyfrom the flat top and extending in the longitudinal direction alongopposed side edges of the flat top. Preferably the retainer lips arewider in a lateral direction than the ribs and protrude upwardly fromthe flat top greater than the ribs.

The support block may include a pair of opposing solid end portionscomprising continuous elastomeric material spanning between the flat topand the flat bottom of the block.

When two support blocks are used to commonly support a roof object, thesupport blocks are preferably spaced apart from one another beneathopposing sides of the roof object to commonly support the roof objectspanning between the two support blocks.

According to another aspect of the present invention there is provided asupport system for supporting objects providing vibration dampening,said system comprising:

at least two support blocks for supporting objects on a roof comprisinga substantially hollow block of a self damping elastomeric materialhaving a substantially flat bottom, two end walls perpendicular to thebottom, and a flat top wall; and

a channel secured to the top wall of each of the least two supportblocks interconnecting the at least two support blocks providing aplatform for supporting objects.

This aspect of the present invention provides a superior vibrationdampening sleeper support for large objects. For example, HVACequipment, cable trays, roof walkway systems, and refrigerationequipment require supports to spread their weight over larger surfaceareas. The use of multiple interconnected support blocks provides aneconomical solution for supporting large objects.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which illustrate exemplary embodiments ofthe present invention:

FIG. 1 is a perspective view of a support system illustrating a firstembodiment of a support block.

FIG. 2 is a bottom view of the support block according to FIG. 1.

FIG. 3 is a perspective view of the support system using the blockaccording to FIG. 1, shown with a galvanized steel channel secured toits top wall.

FIG. 4 is a perspective view of the support system using two supportblocks according to FIG. 1 with an interconnecting galvanized steelchannel.

FIG. 5 is a perspective view of the support system using the blockaccording to FIG. 1, shown with an extendable galvanized steel channel.

FIG. 6 is a perspective view of the support system using the blockaccording to FIG. 1, shown with a roller support.

FIG. 7 is a perspective view of the support system using the blockaccording to FIG. 1, shown with a galvanized steel strut.

FIG. 8 is a perspective view of the support system using the blockaccording to FIG. 1, shown with a variable angle support.

FIG. 9 is a perspective view of a second embodiment of the support blockfor use with the support system according to the present invention inwhich the top side of the block is illustrated.

FIG. 10 is a perspective view of a bottom side of the support blockaccording to FIG. 9.

FIG. 11 is a side elevational view of the support block according toFIG. 9.

FIG. 12 is an end elevational view of the support system using twosupport blocks according to FIG. 9 to commonly support a roof objectthereon.

FIG. 13 is a perspective view of a further embodiment of the supportblock for use with the support system according to the present inventionin which the top side of the block is illustrated.

FIG. 14 is a perspective view of a bottom side of the support blockaccording to FIG. 13.

DETAILED DESCRIPTION

Referring to the accompanying drawings, there is illustrated a supportsystem generally indicated by reference number 5 comprising at least onesupport block 10. Although various embodiments are shown in theaccompanying figures, the common features of each will first bedescribed herein.

The block 10 is moulded from recycled tires. The support block has endwalls 11 perpendicular to a flat bottom wall 12 and a flat top wall 13.The underside of the support block has hollowed out cavities 14.

The block is moulded into lengths and cut to a specifically sized unitaccording to the application. In use, the support block is placed on aroof 20 beneath a roof object 22, for example a pipe. The support devicecan be adhered to the roof surface if desired with polyurethaneadhesives. The elastomeric construction of the support provides sounddampening of vibrating objects. In addition, the vibration dampeningnature of the block prevents excessive wear to the roof.

In each instance, the support block is mounted between the roof objectand the roof such that the roof object is supported on the flat top ofthe support block and the elastomeric material which forms the supportblock is arranged to dampen vibration between the roof object and theroof. Accordingly the support block of the support system is suitablyarranged for supporting vibrating roof objects thereon, for examplerooftop mechanical equipment for a building. The blocks 10 can be formedof recycled rubber in such a manner that the properties of the resultingelastomeric material are self dampening to optimize vibration dampeningbetween the roof object and the roof.

As shown in FIGS. 1 through 8, a first embodiment of the support block10 is shown. The support block 10 according to the first embodimentincludes a flat top wall 13 which is elongate in a longitudinaldirection of the block extending between the opposing end walls 11 ofthe block which are perpendicular to the longitudinal direction. Theblock further includes a pair of side walls 24 extending in thelongitudinal direction between the end walls 11 which slope downwardlyand laterally outwardly from the narrow top wall 13 to the flat bottomwall 12. The bottom wall 12 is much wider in the lateral direction thanthe top wall to provide lateral stability to the block. The hollowcavities 14 are open to the flat bottom wall 12 of the block and aresuitably sized to occupy a major portion of the block so that a majorityof the block is hollow. A divider wall 26 spans between the sloped sidewalls 24 and between the top wall and bottom wall of the block betweenadjacent cavities 14 to provide additional support to suspend the topwall above the hollow cavities 14.

As shown in FIGS. 3 through 8, the support system 5 includes agalvanized steel channel 31 secured to the top wall 13 of the supportblock of FIG. 1. In each instance the channel 31 is generally U-shapedin cross section, having a base 35 secured to the top wall and a pair ofupright flanges 36 extending upwardly from opposing sides of the base toan open top end 37 of the channel. The base 35 is elongate in thelongitudinal direction of the block and extends the full length of thetop wall 13 between the end walls of the block. The upright flanges alsoextend in the longitudinal direction along opposing edges of the base todefine sufficient space between the flanges for receiving suitablemounting brackets therebetween upon which the roof object can besupported.

In FIG. 3, the channel 31 is secured directly to the top wall 13 withself-tapping screws (not shown). Pipe clamps 32 can be mounted tochannel 31 so as to securely fasten a gas or refrigeration pipe to thesupport block.

In a further arrangement of the support system 5 as illustrated in FIG.4, two spaced apart support blocks 10 have the galvanized steel channel31 secured directly to the top wall of each support block withself-tapping screws (not shown) to span between and interconnect theblocks. This embodiment of the support device is sometimes referred toas a sleeper support. This superior vibration dampening sleeper can beused for supporting a variety of large rooftop objects, for example HVACequipment, cable tray, roof walkway systems and refrigeration equipment.

As shown in FIG. 5, in a further arrangement of the support system 5,the support block 10 has the galvanized steel channel 31 securedparallel to and spaced above the top wall 13 by threaded rods 52spanning vertically between the channel and block. The rods are securedby suitable nuts 53 and washers 54. When securing the channel 31 to theblock 10 in this manner, the channel can be raised or lowered to thedesired position in relation to the block by turning the nuts mounted onthe threaded rods. Pipe clamps 55 can be mated to channel 31 so as tosecurely fasten a gas or refrigeration pipe to the support block.

As shown in FIG. 6, in an alternative configuration, the support system5 also has the galvanized steel channel 31 secured directly to the topwall 13 of the block with self-tapping screws (not shown). A galvanizedsteel roller clamp 62 may be secured to the galvanized steel channel 31in which the roller clamp 62 includes a roller supported for rotationabout a horizontal axis, parallel to the channel 31 and the top wall 13of the block. The roller is shaped such that the end portions have alarger diameter than the middle portion to act as a cradle which centresa pipe thereon. The diameters and the degree of taper depend on the sizeof pipe to be supported.

As shown in FIG. 7, in a further arrangement, the support system 10again has the galvanized steel channel 31 secured directly to the topwall 13 with self-tapping screws (not shown). In this instance, verticalsteel struts 72 connect to channel 31 with the aid of fittings 73. Thevertical steel struts 72 are spaced apart and joined adjacent top andbottom ends by cross-members 74 to provide rigidity to the rectangularsupport platform. This support device is particularly useful forsupporting large rooftop ductwork.

As shown in FIG. 8, the support block 10 again has a galvanized steelchannel 31 secured directly to the top wall 13 with self-tapping screws(not shown). In this instance however, a variable angle support leg 82is secured to the channel 31 by means of securing means 83, whichsecuring means 83 may be a bolt (plated) and nut with locking washer. Inuse, the securing means 83 are loosened, the variable angle support leg82 rotated into the desired position, and the securing means 83tightened to retain the variable angle support leg 82 at the desiredangle.

Turning now to FIGS. 9 through 14, a further embodiment of the supportblock 10 is illustrated in which the block is elongate in a longitudinaldirection between the ends 11. The flat top 13 and flat bottom 12 havesubstantially identical rectangular dimensions with both lyingperpendicular to vertical side walls 24 extending in the longitudinaldirection between vertical end walls 11. Although the block 10 is shownin two different sizes in FIG. 9 and FIG. 13 respectively, in eachinstance the block 10 is plural times longer in the longitudinaldirection between the opposing ends than the width in the lateraldirection between opposing sides 24 while the width in the lateraldirection between the opposing sides is also plural times a height ofthe block between the flat top and flat bottom. The blocks 10 accordingto FIGS. 9 through 14 include end portions 90 which are solid inconstruction having continuous elastomeric material between the flat topand flat bottom of the block.

Ribs 92 are formed in the flat top 13 of the block to form elongateprotrusions projecting upwardly from the flat top and extending in thelongitudinal direction parallel to one another and spaced laterallyapart from one another. The ribs define grooves extending in thelongitudinal direction between each adjacent pair of ribs. The ribs 92are integrally formed of the elastomeric material with the block andassist in the vibration dampening properties of the block.

A retainer lip 94 is provided along the top wall 13 at each of the twosides 24 extending in the longitudinal direction. Each retainer lip 94comprises a projection extending upwardly beyond the top wall 13similarly to the ribs 92, but having dimensions which are wider in thelateral direction than individual ribs, as well as being taller in avertical direction relative to the ribs so that the lips 94 projectupwardly from the top wall greater than the ribs. By arranging theretainer lips to project upwardly from the top wall beyond the ribs 92,the retainer lips function to retain feet 96 of a roof object 22 on thetop wall 13 of the blocks between the sides 24 thereof.

The blocks 10 according to FIGS. 9 through 14 also include flow channels98 formed in the flat bottom 12 of the block. Each channel comprises athrough channel extending in the lateral direction, perpendicularly tothe longitudinal direction of the block so as to communicate betweenopposing longitudinally extending sides 24 of the block. Each channel 98includes a main portion communicating between a pair of mouths 99situated at the sides 24 of the block respectively so that each channelmain portion spans and communicates between a respective pair of mouths94 which are larger in cross sectional dimensions than the channel. Themouths 94 taper from the respective side 24 at an outer end, inwardlytoward a main portion of the channel 98 of less cross sectionaldimension so that the mouths each function to gather water collected atthe sides 24 of the block and redirect the flow of water through therespective channels 98. In this configuration the flow channels 98 donot impede the flow of water across a roof so that water is notpermitted to gather at sides of the block and potentially cause a leakin the roof. The hollow cavities 14 are provided in the flat bottom 12of the block between each adjacent pair of channels 98.

In the embodiment of FIG. 9, the overall block is shorter in length thanthe block according to FIG. 13 and accordingly only two flow channels 98are provided for locating a single cavity 14 therebetween. When theblock 20 is longer as shown in FIG. 13, three through channel 98 areprovided for locating two cavities 14 therebetween. In each instance theflow channels 98 are evenly spaced from one another along thelongitudinal direction of the block.

As shown in FIG. 12, the elongate shape of the blocks 10 according toFIGS. 9 through 14 readily permit the blocks to be used in pairs mountedspaced apart and parallel to one another at an adjustable spacing sothat the resulting support system 5 defined by the pair of blocks canaccommodate various dimensions of roof objects by simply locating theblocks 10 at varied spacing relative to one another. As shown in theexample of FIG. 12, the support system 5 is arranged so that one of thesupport blocks 10 is provided along each opposing side of the roofobject 22 supported commonly on the pair of blocks 10.

While specific embodiments of the present invention have been describedin the foregoing, it is to be understood that other embodiments arepossible within the scope of the invention. For example, someapplications may require enhanced vibration dampening. In this case, thesupport blocks could be moulded from a material of reduced rigidity orbe moulded from materials to create layers of differing rigidity withinthe block. The invention is to be considered limited solely by the scopeof the appended claims.

1. A method of forming a support block for supporting a roof objectcomprising rooftop equipment on a roof of a building, the methodcomprising: providing a flat bottom arranged to be supported on theroof; providing a pair of opposing end walls oriented perpendicularly tothe flat bottom of the support block; providing a top wall which iselongate in a longitudinal direction extending between the opposing endwalls and which is arranged to support the roof object thereon;providing a pair of sloped side walls extending in the longitudinaldirection of the top wall between the opposing end walls and extendingdownwardly and outwardly in a lateral direction from the top wall to theflat bottom of the support block such that the flat bottom is wider inthe lateral direction than the top wall; forming a pair of hollowcavities which are open to the flat bottom; providing a divider wallspanning between the top wall and the flat bottom between the hollowcavities; and forming the flat bottom, the pair of opposing end walls,the top wall, the pair of sloped side walls and the divider wall from asingle piece of a self-damping elastomeric material such that thesupport block is arranged to be supported between the roof object andthe roof and the self-damping elastomeric material forming the supportblock is arranged to dampen vibration between the roof object and theroof.
 2. The method according to claim 1 including forming the supportblock from recycled rubber tires.
 3. The method according to claim 1including forming the hollow cavities to occupy a majority of thesupport block such that a majority of the support block is hollow. 4.The method according to claim 1 including forming the divider wall so asto be arranged to support and suspend the top wall above the hollowcavities.
 5. The method according to claim 1 including: providing arigid channel member; fastening the rigid channel member onto the topwall of the support block; and supporting the roof object on the rigidchannel member.
 6. The method according to claim 5 including forming thetop wall to be flat and mounting the rigid channel member against theflat top wall using threaded fasteners.
 7. The method according to claim5 including forming the rigid channel member to be generally U-shaped incross section, having a base secured to the top wall of the supportblock and a pair of spaced apart upright flanges spanning upward fromthe base to an open top end of the channel.
 8. The method according toclaim 1 including moulding a plurality of support blocks as a singlelength and cutting the support blocks from the single length.
 9. Amethod of supporting a roof object comprising rooftop equipment on aroof of a building, the method comprising: providing a support blockformed from a single piece of a self-damping elastomeric materialcomprising: a flat bottom; a pair of opposing end walls orientedperpendicularly to the flat bottom of the support block; a top wallwhich is elongate in a longitudinal direction extending between theopposing end walls; a pair of sloped side walls extending in thelongitudinal direction of the top wall between the opposing end wallsand extending downwardly and outwardly in a lateral direction from thetop wall to the flat bottom of the support block such that the flatbottom is wider in the lateral direction than the top wall; a pair ofhollow cavities formed in the elastomeric material which are open to theflat bottom; and a divider wall spanning between the top wall and theflat bottom between the hollow cavities; and supporting the flat bottomof the support block on the roof; and supporting the roof object on thetop wall of the support block such that the support block is supportedbetween the roof object and the roof and the self-damping elastomericmaterial forming the support block dampens vibration between the roofobject and the roof.
 10. The method according to claim 9 includingsupporting a plurality of support blocks spaced apart from one anotheron the roof, each being formed of a single piece of self dampingelastomeric material, and commonly supporting the roof object on theplurality of support blocks.
 11. The method according to claim 9including: providing a rigid channel member; fastening the rigid channelmember onto the top wall of the support block; and supporting the roofobject on the rigid channel member.
 12. The method according to claim 11including forming the top wall to be flat and mounting the rigid channelmember against the flat top wall.
 13. The method according to claim 11including fastening the rigid channel member to the top wall of thesupport block using threaded fasteners.
 14. The method according toclaim 11 including forming the rigid channel member to be generallyU-shaped in cross section, having a base secured to the top wall of thesupport block and a pair of spaced apart upright flanges spanning upwardfrom the base to an open top end of the channel.
 15. A support block forsupporting a roof object comprising rooftop equipment on a roof of abuilding, the support block comprising: a flat bottom arranged to besupported on the roof; a pair of opposing end walls orientedperpendicularly to the flat bottom of the support block; a top wallwhich is elongate in a longitudinal direction extending between theopposing end walls; a pair of sloped side walls extending in thelongitudinal direction of the top wall between the opposing end wallsand extending downwardly and outwardly in a lateral direction from thetop wall to the flat bottom of the support block such that the flatbottom is wider in the lateral direction than the top wall; a pair ofhollow cavities which are open to the flat bottom; and a divider wallspanning between the top wall and the flat bottom between the hollowcavities; the flat bottom, the pair of opposing end walls, the top wall,the pair of sloped side walls and the divider wall being formed from asingle piece of a self-damping elastomeric material; and the top wallbeing arranged to support the roof object thereon such that the supportblock is arranged to be supported between the roof object and the roofand the self-damping elastomeric material forming the support block isarranged to dampen vibration between the roof object and the roof. 16.The support block according to claim 15 wherein the support block isformed from recycled rubber tires.
 17. The support block according toclaim 15 wherein the divider wall is arranged to support and suspend thetop wall above the hollow cavities.
 18. A support block in combinationwith a roof object comprising rooftop equipment supported on a roof of abuilding, the support block comprising: a flat bottom supported on theroof; a pair of opposing end walls oriented perpendicularly to the flatbottom of the support block; a top wall which is elongate in alongitudinal direction extending between the opposing end walls; a pairof sloped side walls extending in the longitudinal direction of the topwall between the opposing end walls and extending downwardly andoutwardly in a lateral direction from the top wall to the flat bottom ofthe support block such that the flat bottom is wider in the lateraldirection than the top wall; a pair of hollow cavities which are open tothe flat bottom; and a divider wall spanning between the top wall andthe flat bottom between the hollow cavities; the flat bottom, the pairof opposing end walls, the top wall, the pair of sloped side walls andthe divider wall being formed from a single piece of a self-dampingelastomeric material; and the roof object being supported on the topwall such that: the support block is supported between the roof objectand the roof; and the self-damping elastomeric material forming thesupport block is arranged to dampen vibration between the roof objectand the roof.
 19. The support block according to claim 18 wherein thedivider wall is arranged to support and suspend the top wall above thehollow cavities.
 20. The support block according to claim 18 furthercomprising a rigid channel member fastened onto the top wall of thesupport block by threaded fasteners, the rigid channel member supportingthe roof object thereon.